Process for fabricating terminal connectors from sheet metal



1955 J. R. VICKERY PROCESS FOR FABRICATING TERMINAL CONNECTORS FROMSHEET METAL Original Filed July 2'7, 1944 5 Sheets-Sheet l INVENTOR Jaw1e V/oa-aev BY .2274 ATTQRNEY s 1955 J. R. VICKERY PROCESS FORFABRICATING TERMINAL CONNECTORS FROM SHEET METAL Original Filed July 27,1944 5 Sheets-Sheet 2 INVENTOR Ja /VA. WCAAK). Y M

ATTORNEYS J. R. VICKERY PROCESS FOR FABRICATING TERMINAL Feb. 8, 1955CONNECTORS FROM SHEET METAL Original Filed July 27, 1944 5 Sheets-Sheet3 iNvENTOR JEHN 16? WcKEEY lav/WW1.

ATTORNEYS Feb. 8, 1955 J. R. VICKERY 2,701,778 PROCESS FOR FABRICATINGTERMINAL CONNECTORS FROM SHEET METAL Original Filed July 27, 1944 5Sheets-Sheet 4 INVENTOR Jay/v Ware-Ry BY W a! I ATTORNEYS 1955 J. R.VICKERY 2,701,778 PROCESS FOR FABRICATING TERMINAL CONNECTORS FROM SHEETMETAL Original Filed July 27, 1944 5 Sheets-Sheet 5 if 76 m0 a '70 A I x6 78 742 IVW INVENTOR 759MB MCKfEY ATTORNES United States Patent OPROCESS FOR FABRICATING 1 CONNECTORS FRQM -SHEET METAL 3 .Iohn:R-.-Vickery,:York, Pa.',=-assignor to Aircraft-Marine Products Inc.,Harrisburg, Pa.; at. corporationfofaNew i Jersey flrigiual'applicationnluly 27,. "1944,: Seria1-' No.- 546 835. JDividedand thisvapplication October 1,: 1949, .Serial "iThi's invention .relates" tobrazing processes-and to articles made thereby,:particularly to aprocess fortautoj matica'lly brazing the ferrule-seam of, an electric.terrni'nal infwhich the ferrule is'forrned" by rolling up afiatfblankGland bringing-the ends close together in abut seam. Th s application isa divisionofmy-copending application, Serial No.'546,835, filed'luly 27,1944, now PatentNo. 2,549,-

868. Terminals for electric. conductors having rolled ferrules havelongbeen used but are open to-the objection .whenjc-rimped. ontothe endof a wire. orcable', etc., that the 2 .,=-seam is apt to spread open. atthe point .where.t-he rolled 'edges' abut,unlesscarefully.designedldies.are used wlth ..the lseam .properly. oriented: in. the. dies.Furthermore in electrical. connectors oftthis .type, .it isdesirabletohave -n-the-ferrule dead soft so that. it. may be readily and perma-.nently .formed onto a wire. or. .thelike, and atthe same 1 .-time tohave the tongue portion work'hardened.

In .the past a relative increase. in'th'e hardness of the=tonguetmayhave occurred. by the swaging of.- the--tub1ng 'at oneend.-.to..form.,a work hardened.,tongue."T-his 3 5 having all. theadvantages of'one made; by deept jdrawing orjextruding; .etc., while.retaining; the..-.reco'gnized .advantages of a; ferrule mad'e 'by'stampingiand rolling; up

I from flat sheet or strip. It is another object: of'thisinvention toprovide, an electrical-connector; characterized by a fullyannealedferrule, a workhardenedctongue" and lan' integral-neck ofpartlyannealedmaterial-acting" to connect the'ferruleto the tonguewith'out presenting any. 50 'Qsharp line of demarcationwhich'issusceptiblelofbe'comiing a line of'brealgage.

A further object of the 'inventiontis to'etfect the, brazing of aseam'sirnultaneously-with .a heaLtreatingin the ",same operation.

A further object is to provide ;a process torproduce a rolled ferruleterminalconnector,andparticularly those :made of copper; in which,thei'ferrule is fullyann'ealed so as tobe suitable for crimpingwhile'the'tonguei or itermi-' nal' connector part of the terminalretains the properties and ,crystallinestructure developed thereinduringcold working of themetal.

;To. this end the invention contemplates so. holdin'gthe terminalconnector to be brazed withits tongue between 1 relatively cold meta-ljaws of relatively .high heat capacity ..while .theterrule is heated toatemperatureesuitable for brazing that by reason oftherapid conduction.fron'rthe =--"ly in thetorm of 'a-wire or ther strip ,.in"such manner80 that it: extends lengthwise ofz zthe -seam: and: ar'a11'e1 to2,701,778 31 Patented Feb. 8, 1955 2 iti'sd'that. itiisbroughtL'intoconta'ct withiftheflferrule -throughout' the length 'of.thesearn, thusinsuringcornplete filling of the seam and any recesses,depressions; or cavities therein, and automatically melting offfrom'hthe wire or otherstripfjust the amount of brazing mtal'ret quiredfor "the seam.

:An important featureof the invention isvin controlling "the feeding-ofthe brazing material into apositionwhere it is contacted by 'aheatedferrule,by means ofthe ferrule I'-its'elf, thus preventing excessivefeeding of unusedibrazing "material in the event that one or morefer'rulesshouldfbe omitted from a, series approaching the brazing:point.

" Another important feature of the invention is the non- "ixtr'ol ofthedelivery of .terminals to the clamping jaws;vby

5the movement of the jawsinto' receiving relation to a ":raceway andtheir closinggby movement away from the raceway.

' "'Other objectsrand'important features: of the: invention to 'whichreference has not .been made:hereinabove".'will 0 be apparentwhen the.followingdes'cription'and claims I are considered in connection 1 withthe. accompanying drawings.

n Although in the accompanying drawings I have shown "1a"preferred;embodimentof my invention and have der"S (i1'-ib6d the"same'and suggested various; modifications it thereof in this;specification, it is. to beiunderstood' that these arenot intended to beeither exhaustive orlimitjng *ofxthe invention, abut, on;the*contrary;are chosen 'for the purposes of"illustrating.the inventioninorderthatiothers skilled in .the art. may so'fully'understand'theinvention, its principlesand' the; application thereofithat they .may"embody itan'd' adaptit in numerous forms; eachxas may ';be' best suitedto the requirements of'its 'particularuse.

In the/drawings, 5 F'Eigure '1 is. aside'elevation of amachine-embodying sthepresent invention for use inbrazing the ferrulejoints ofkel'e'ctric conductor terminals;

FigureZ. is. a. fragmentary elevation takenfrom'the "opposite"sidewshowingzvarious;hiddenr. parts :inbroken tw e F1gure31satopplanview'ofthe'cmachineshown' in igure 1;

Figure 4 is.a fragmentary View.inperspectiveshowjng a" portion of thecarrier disc and, adjacent parts relating "to the'final.orientation of'the' work in. theclamp andsthe --"aetual-hr'azing operation;

I Figure 5;is a 'fragmentary'view; in central'vertical-sec- "-tionshowing the uppermost portion of the ..carrier-'disc and adjacentmechanism for feeding. and orienting-"the work on the. carrier disc;Figure 6-is 'afragmentaryyiew takenioniline 6 6 of Fig1-1r'e'5; and

IEigur'e "7 is a perspective view of .a completed electricalterminala'fter passage through" the machine shown in the 1. otherfigures. .iInKtheiillustrativeLrembodiment' of the invention. the'"--xntechanism"fqr presenting theterminals successively to "the brazingmeans, :heatinglthemuand; applying the "brazying-material'are' *allimountedon 'a commonframe which, as shown,ismadequp.oftwo'pairsxofvertical angle bars 0" 2' and 4;'C01'iSlZitllfilf1g"Ih6 "legs and "upright main "frame -me'rnbers of themachine, cross angle bars 6 and 8, con- .-i anectlng 'the verticalanglebars 21am 4 and forming-sup- 1w: ports for-further pairs offrontand-rearvertical angle bars-1.0 and 12,. ilongitudinal bars 14-and16," connecting .athertverticali;angle zbarsr.2*z-and 4 at t-theinxtops,tcrossbars t ti18,:andt20;rconnecting Ffhfi two: verticahanglebarisizand 4-,;tand-,.--. on each side} of-.:the machine, a shelf;22;?which serves as support for the;driving"IIlOtOI?;-24E,6I1d11'f012th6 ansmissionhousing -26. 7.The..housinge26-may haverthereinzanyusuitableaspeed L,reducing-transmission, e. g.,. as aaworm. andtwormwvheel I (notshown)for driving. the..shaft.: 28,. which .hastfixed thereon the V-belt.pulley 30 v by which, .the...mechanism, hereinafter to be described,isfldriven/ .Al'so supported 750114138 cro ssbar's 22 is a.ree'l32 fromwhich is drawnthe wire"-3 4-"o'f brazing material; for example anysuitable commercial"'brazing alloy, advantageously 10f "the""self ifluxing type Whichradil-y =wets the' sdlidmetal andruns 'into' 'thecapillary:crack"betweenthe :abuttedf edges. A :isuitable alloy for thepurposes of the-present invention is a: composed of f5% silver;%-=copper' andF S %-"phosphorus, i. e. about 2.5% less phosphorus thanthe silvercopper-phosphorus eutectic.

The carrier for the terminals to be brazed comprises, as shown, arotatable carrier disc having a notched periphery and also havingperipherally extending grooves, at least in the clamping portions of theserrations. This carrier 36 is mounted on a shaft 38 having its hearingsin bearing supports 40 and 42 bolted upon the respective crossbars 14and 16. The carrier 36 is keyed or otherwise fixed to the shaft 38 toturn therewith. Also keyed or otherwise fixed to an extension of theshaft 38, beyond its bearing 42, is a ratchet wheel 44 by which thecarrier 36 can be intermittently turned to bring successive clamps intothe various operative positions necessary to perform the functions ofthe machine.

The V-belt driving pulley 30 is connected by the V-belt 46 to a largerV-belt pulley 48 on a shaft 50 having its bearings in bearing supports52 and 54 bolted upon the respective crossbars 14 and 16. The pulley 4-8is keyed or otherwise connected to the shaft 50 to turn therewith. On anextension of the shaft 50 beyond the bearing member 54 is keyed a pitmanwheel 56 having therein a crank pin 58 for reciprocating thepawl-operating bar 60. At its upper end the pawl-operating bar orconnecting rod 60 is pivotally connected at 62 to a pawl-carryingrockarm 64 arranged to rock about the shaft 38 so that its rockingmovement is concentric with the rotation of the ratchet wheel 44. A pawl66 is pivoted at 67 on the rockarm 64 and the pawl is urged intoengagement with the successive teeth of the ratchet wheel 44 by a spring68 connected at one end to a pin extension on the pawl and at its otherend to pin 69 carried by the rock-arm 64.

The carrier 36 has mounted thereon a succession of clamps whichcooperate with the surfaces of the notched edge and with the groovestherein, to clamp the terminals which are to be brazed and hold them inthe successive positions where they are operated upon when the carrieris rotated step-by-step. Each of these terminal clamps comprises a noseportion 70, adapted to be received within the opening 126 in theterminal clamped thereby, the nose preferably also entering the groove74 in the clamping face of the carrier. The nose 70 is formed on thecentered arm 76 of a bellcrank 78 fixed to a short shaft 80 extendingthrough a bearing hole in the carrier 36, the other arm 82 of thebellcrank (shown in broken lines in Figure 2, since it lies behind thecarrier 36) extends toward the center of the carrier 36 and is arrangedto be engaged by a cam 96 hereinafter to be described. On the front sideof the carrier, as viewed in Figure 2, is the third arm 84 of thebellcrank '78, this arm being connected by a spring 86 to a flange 88 atthe hub of the carrier 36.

The spring 86 tends to hold the nose 70 in clamping relation to thenotched face of the carrier 36, except when the arm 78 is moved out ofsuch clamping relation by engagement of the arm 82 with the cam 96hereinafter to be described. The arm 84 is also provided with an upperface 92 for a purpose hereinafter to be set forth.

An arm 94 on the rocker arm 64 carries a cam 96, shown in broken linesin Figure 2, this cam being adjustable on the arm 94 by means of theslot 95 through which passes the clamping bolt 97. It will be seen thatthe high part of the cam begins at the point A in Figure 2 and extendsto the point B, beyond which there is a short valley C and then anotherhigh dwell D. The purpose of the dwell D is to open the terminal clamp,preparatory for reception of a terminal. Beyond the dwell D the cam 96releases the arms 82 in turn so that the arm 78 of each is pulled downby its spring 86 and thereby holds a terminal 100 clamped under its nose70 until the carrier 36 has made a half turn, when the arm 82 againmeets the cam 96 and is swung out at the point A, so as to release thearm 78 and drop the terminal into the chute 209.

By reason of the mounting of cam 96 on the arm 94, it moves forward withthe carrier 36 and thus the cam actions just described occur only on thereturn stroke of the ratchet crank 64-95 when the carrier 36 is at rest.

A raceway 98, shown more clearly in Figure 2, is provided for feedingthe terminals 100 successively into the clamps on the carrier 36. Thisraceway comprises as its floor an inclined bar or frame member 102adjustably connected by lugs 104 and 106, respectively, to crossbars 108and vertical bars 110 of an upper frame. This mounting of the raceway 98provides for gravity feed of the terminals into position to beintroduced into the successive terminal clamps on hte carrier 36.

At the bottom of the raceway 98, the terminals strike the retaining andreleasing finger 112 on the weighted bellcrank 114 pivoted at 117. Boththe finger 112 and the Weight 118 are adjustable to adapt the mechanismfor feeding of ditferent terminals. The weight 118 on the arm 116 servesto return the member 112 to its operative terminal-retaining positionafter each feeding operation. The downward movement of the arm 116 islimited by a shaft 120.

From the foregoing description it will be seen that, when one of theterminal clamps comes under the terminal retainer 112, in the rotationof the carrier 36, its arm 82 is in the valley C of cam 96 so that thebellcrank 78 can pass under the arm 112 without disturbing its position.When the step movement is complete, the arm 84- is under the bolt 128 onthe stop arm 132; and, therefore, when the return movement of the cambrings the high point D under the arm 82 of the bellcrank 78 to open theterminal clamp at 70, the action is also transmitted to the stop arm 132thus releasing the line of terminals held by the pin 140, thus allowingthe lowermost terminal to drop into position under the clamping nose 70on the arm 76. This position is established by the finger 112.

As the cam 96 moves to the end of its return stroke, the dwell D passesout from under the arm 82, whereupon the arm 76 drops and its nose 70engages in the eye 126 of the terminal 100. At the same time the arm 132drops back to its normal position so that its stop-pin 140 is in frontof the ferrule of the next terminal 100, so that the column of terminalsis held above the pin 140 until after the next step movement. When thespring 86 closes the clamp 78, this closing causes the nose 70 on theclamp to enter the opening 126 in the tongue of the terminal, and thusnot only to clamp it firmly upon the carrier, but also so to locate itthat its ferrule will be in proper position for the brazing operation.

The retainer 112, being held only by the weight 118, rides over theterminal 100 and then moves back to operative position by action of theweight 118, when the carrier 36 is rotated to the next step.

The bolt 128, as shown, is adjustably screwed into the lever 132 andsecured by a lock nut 134. The lever 132 is fulcrumed upon thestationary shaft and is bent upwardly at its left hand end, as seen inFigure 1, so that this upwardly bent end is approximately parallel tothe raceway 98. This end of the lever 132 is also slotted,

. as shown at 136, to provide for the adiustment of a slide 138 mountedthereon. The slide 138 is provided near its lower end with a retainingpin 140 arranged to hold back in the raceway 98 the terminal which isnext above the one retained by the retainer 112. It will be seen thatthis retaining pin 14-0 still retains the terminal 100 which is nextabove the one on the retainer 112, when the latter terminal is moved outfrom the raceway 98 by further movement of the carrier 36.

The terminal, which has been fed into the clamp in the manner describedand which has been clamped on the carrier 36, as shown in the upper partof Figure 2, is carried in the stepwise movement of the carrier 36 firstpast the funnel guide 210, where any misalignment of the terminals iscorrected, and at the next step into the position, shown at E in Figurel, in which the terminal strikes the feeler 188 for the purpose morefully explained below. The next step of the carrier 36 brings theferrule of the terminal to the position where it is heated by the fixedtorch 144.

It will be noted that the clamping of the terminal in each of the clampsis done in such a way that the tongue is held flat against the slopingface of the notch in the carrier 36 while the ferrule projects outbeyond the periphery of the carrier and is thus freely exposed to theconcentrated flame of the torch 144, the nozzle of which is shown at142. This torch, as shown, may be of a type well known and commonly usedfor brazing and welding. Gas is supplied by a flexible hose 146, andvalves 148 and 150 serve to control the flame to concentrate it on theferrule. This flame is advantageously of a slightly reducing characterto prepare the surface for the brazing material.

As shown particularly in Figure 2, the flame of the torch 142 isdirected against the ferrule of the terminal 100, which is at rest infront of it so long as the carrier ---36 is at rest'betweemits'successive step movements. The .torch is, however, so adjustedthat'thiswill be'sufiicient to heat the ferrule of the terminal to abrazing-andanhealing temperature,e. g. above about 1300 F.

' The brazing-material'-"34, which is to-beused to braze or soldertogether the two' edges of,- andtoseal the' seam 'in, the'fer-rule of'th'e 'terminal1c00, is in'continuous strip form,' advantageouslyawire."- This wire -34 is guided through a tube 154 into a position inthe path of and parallel-with the seam, as the terminal moves on thecarrier '36--away from'the' heating-station F. At its other end-the-t11be'154 receivesthe'wire 34from a feeding device.

' The end o'f the wire-guiding tube-154 which is adjacent to the pointof use is-held in a holderl56having a threaded stem l58-arranged-tobelocked in the desired angular positior'r-by-nuts 160 in a-'bracket.arm'162,. adjustably connected to an upright-"angle bracket 164 "boltedto I the crossbar 14- of the-mainframe. The 'lower end. of

-'the 'tube' 154 is :mounted on a feeding table 166 bolted -tothe-crossba'r 14. jThe*wire 34,--beyond this tube, passes through-guideeyes--167"from-thereel-32, and. across the -tabletl66. The wire is'-fed-step-by-step into the tube 154 i bythe knife-like end 168 of afeedingdog. 170 pivoted on the connecting rod-60.

I -As shown in Figure 2, the connecting rod.6tl is slotted and thefeeding'dog"170 is pivoted at172insaid slot, a 'portionzof thisfeedingdog 170 extending. above the connecting rod--60 where it maybeengaged byan adjustable's'top '174" threadedthrough azbracket 176mounted upon the upper side' of the'connecting' rod 60. The stop 188)and-the end 'ofzcrankzarm 204 'whichfiormsthe hinge pin *ona-'plate-206.This hinge'pm, as shown, is

pivoted on plate 18350 that the 'twoplates' can be aligned -toprovidea'tr'ack'for'thewheel;184 and thus 'hold'the knife :edge "168abovethe'wire, or plate 206. is swung away when th'e-feeler-188'is:held out by a ferrule', and

thus the knifeedg'e' is allowed to drop-onto the-wire to effect feedingthereof 'on'thereturnstroke of. thecona nec-ting rod 60.

When,- however; the-parts are inp'ositionshown inFigure 2; that is, withno terminal in" POSIUOII' 1n theclamp adjacent to the feeler 188, thecounterweight 196 is preferably so adjusted on the threadedangular'eXten'sion'194 of the shaft 195 that it"alm'ostcounterbalancesthe.pull

of-the link 202- and the parts-connected-therewith, but

- leaving enough'unb'alan'ced'pull to-swing the plate-206 'against'thetable166-when the feeler 188 finds no-termina1-on the carrier' 365 If,however, the ferrule of a termi- -nal be movedforward toward the brazingposition, be-

neath the feeler 1 88-,- on the step movement of the .car-

rier 36, then the feeler188'willrock the bellcfankgformed -by--the arm190-and the arm'2tl0, in'a'counterclockwise direction (as seenin Figure2):-and thus pull the link'202 I upwardly and swing the plate 206 out ofthe path of .the

wheel 184, so that the-knife edge-168' can drop intolengagementwith thewire +34 "onthe back 'stroke'ofthe =connecting-rod 61). A length of thebrazing 'wire34 will thus be pushed into position to be used, thisfee'dingof the wire 34 'taking place after the movementof the carrier 36'which'brings the terminal into the brazing posi- 1 tion andwhile-the'ferrule is'beingheated tobrazin'g tem- 1 perature.

"174 limits the movement of the dog 170 about the pivot 172, when thedog 170 is pickedz up off the table 166. Since the crank pin 58 on thereturn stroke moves away from the table166, the dog 170 is held awayfrom the wire 34,and therefore cannotdrag it backward. A spring 178,which is-coiled about the pivot' 170, and connected at one end to theconnecting rod.60,.as shown at 180, and at its otherend to apin 182 onthe dog 170, holds '1 the 'knife 16.8- against'the table. 166 during thefeeding operation.

*The pin182also serves as a pivot-for a cam follower 1 184ml the dog170.Thepurpose of the camwheel184 isto hold the dog'170'out of feedingrelation to the wire '--34-'on the table-166'- at the endofits feedingstroke and when there is'no' terminal beingfed into position'to bebrazed.

The plate '183 at the edge of the table 166 provides a cam ortr'ac'fforthewheel -1'84;-.and this plate is adjustably mounted on thetable by bolts'185 received in slots -so that the-cam slope'186 willengage the wheel 184 earlier orlater in the travel of the'dog'170 so asto feed a shorter or longer portion of the'wire 34.

1 It willbe seen that ordinarily the reciprocating movement of theconnecting rod will carry the dog170 up "beyond the -releasing' camf186whereby to'lift the knife 2 The brazing wire 34 is projected into thepath' of the ferrule in a direction such" that it is approximatelyparallel to the seam when it is contactedby the ferrule, but

advantageously at a slightangle so that its end touches the seam firstand it isbent progrossively, holding all parts ofthe-wire against theseamzun-til it is progressively fused by contact with the hot ferrule.

. The -feeler 188 may-be 'sufiiciently' long so that" plate 1 206 isheld outuntil roll-184 is in feeding position on the table 166, or thestop 174 may be adjusted'so that wheel 184 is'held just below the-edgeof' the plate 206 so that it cannot come into-alignment with plate 183until the wheel 184 passed'up the cam slope186.

' The ferrule of. the terminal-100, after having been heated to a redheat during its dwell in the position in front of the heating torch142-,"will then be carried'away from the flame of the tdrchl42by thenextstep rotation or the carrier 36. As the carrierstarts toturn, the

-=heated ferrule of the terminal- 180 engages a 'portionof .168 :fromthe wire- 34; 'and:thatthe action of the spring *the wire 34'whichprojects beyondrthe upper end of the .l I78.will tend to move theknife'edge'168 into engagement -tube"154,' this'contactbeing directlyat" the joint where with: the wire134 to effect-thefeedthereof. Thisengage- -ment;of:the:k'nife: edge .168 with the wire will be onlysufficient to cause it toxbitilightly into the wirefor feeding purposes,withoutseveringTor -cutting through the If .no terminal is-.about tocome into brazing position, it is,.of\ course, notdesirable-thatthe wirebe fed. To prevent thefeeding-of the wire a feeler 188 has beenprovidedv at. thenextstationahead' of that at which heating occurs."This feeler 188 is so connected to the wirefeeding mechanism that, ifthe feeler 188 be not engaged by the'ferruleof a terminal about to bemoved into the heating positionF, the dog.170 will. beheld out offeeding relation-tothe wireyor vice versa, and no length .of brazingwire will be fed.

':As'. shown in'Figures l and'2', the feeler 188 is mounted onan'arm190, held in a' clamping head 192 by which it may be adjusted ona' shaft 194 and clamped'in the proper angular position required fora-given size terminal.

- The shaft 194 has its bearings inthe upper frame members 108; and, asshown particularly inFigure 2, the for- Ward end 195 of the shaft 194 isbent at right angles to 'form a crank. arm which is threaded to receivean adjustable counterweight 196 vbyuwhich the weight of the connections200, 202, 204, etc., now to be described may be almost, but not quite,counterbalanced. Also secured the edgesof the wings of the terminalblank are butted together to-form the ferrule. The red hot ferrulequickly fuses off the required lengthofthe brazing wire and the brazingof the jointwill at once be effected.

The time of the step rest at the station F and the intensity ofheatingby-the fiamefrom the torch 144 are setto bring the ferrule to asuitable annealing temperature'ab'ove. the fiow' point of. the brazingmetal, and the number of steps to therelease station A, where theterminals are'dropped into a quenching bath is chosen. to give anappropriate period for the readjustment of grain structure required forannealing. It will be noted that theheatingof the terminal islocalized.in the ferrule both because the tongue portionof the terminal isheldagainst the cool periphery of the carrier 36 and because the ferrule isheld laterally outward from and above the tongue, while the flame isconcentrated and directed across the ferrule only. Thus thework-hardeningof the tongue, and of any parts'associated therewith,is'substantially retained even though the "the high point A on--the:cam96, the arn182 of its clamp ridesuplonto the high: part A of the cam 96and thus effects-the: release. of. the -terminal. When the clamp 7 0 isthus opened, the released terminal will drop out of the carrier onto thechute 269 and thence into a quenchtng tank 208.

In order that each terminal 100 may have the seam of its ferruleproperly aligned with the brazing wire 34, as it comes into contacttherewith, a pair of funnel guides 210 are arranged in a V, taperingfrom a wide mouth to a narrow exit just wide enough to pass a properlyaligned terminal ferrule. These guides, being arranged beside the pathof travel of the terminals, serve to align each terminal accurately, asit is moved through the V between the guides shortly before the ferrulereaches the point at which it is heated for the brazing operation. Asshown, this straightening device 210 consists of guide plates on boltsadjustably attached to the crossbar 211, which in turn is adjustablybolted through slots 212 to the vertical bar 164 of the upper frame.

From the foregoing description, the mode of operation of the device willreadily be understood. As hereinabove pointed out, the raceway 98 isfilled with terminals to be brazed, with the connector portion (i. e.,the tongue in the type shown in Figure 4) of each terminal extendingdownward in the raceway. With the driving wheel 34 constantly rotatingand slowly effecting the reciprocation of the connecting rod 60 throughthe crank pin 58 on the pitman wheel 56, a step-by-step turning of thecarrier 36 will be effected as the pawl 66 is driven back and forth,alternately engaging and riding over the ratchet 44. As

- the carrier 36 is thus turned in a step-by-step manner,

the successive terminal clamps 70 mounted thereon will be brought intoterminal-receiving position under the raceway 98.

As the carrier 36 moves to this position, the cam 96 moves with it, buton the return stroke of the rocker 64, the cam 96 moves its nose D underthe arm 82 to open the clamp 7t) for reception of a terminal, and at thesame time, through the connected arm 84 to lift the stop 132 and allowthe line of terminals to slide down against the terminal positioningretainer 112. As the rocker 64 nears the end of its return travel thenose D on cam 96 passes beyond the arm 82 allowing it to drop back,under pull of the spring 86, and thereby closing the clamp 70 onto thelowermost terminal, while the return of the arm 84 allows the stop arm132 to drop back into position where its pin 140 will hold the remainingterminals in the raceway 93.

When the carrier 36 moves again the clamp 70 carries the terminal 100with it, pushing the retaining finger 1.12 ahead of the terminal againstthe pull of the weight 118. As the clamped terminal moves away from theraceway, the next terminal moves down against the pin 140 into positionto be delivered to the next clamp during the next operation of the cam96.

Each clamped terminal will have its ferrule projecting from theperiphery of the carrier 36, as it is carried from the raceway towardthe point of brazing, and, as it passes the straightener 210, it will beso aligned that, after heating, its seam will meet the brazing wire 34in good alignment. Thus as it comes into contact therewith on the nextmovement of the carrier, the wire will fuse and flow into the seam bythe heat of the ferrule and will braze and seal the seam.

As above pointed out, the speed of rotation of the carrier 36 and thedistance from the heating station F to the discharge station A arecorrelated to allow a suitable time for annealing of the ferrule, whilethe tongue is still protected from annealing heat by being clamped inthe cold jaws of the terminal clamp. The annealing is concluded onrelease of the terminal at A by dropping it down the chute 209 into aquenching tank 233 as hereinabove described. From the discharge sta tionA to the slope B on cam 96, the clamps 70 are held open, by the longdwell on the cam, so as to facilitate dissipation of heat absorbed fromthe heated terminal.

I claim:

1. In the art of fabricating from sheet metal connectors having a worlhardened tongue portion and an annealed readily crimpable ferruleportion adapted for cold forging onto conductors and the like, thatimprovement which comprises the steps of providing a connector elementof work-hardened malleable sheet metal having tongue and rolled upferrule portions, said ferrule portion having a longitudinal butt seamtherein; heating said ferrule portion to a temperature in excess of theannealing temperature of said sheet metal and the wetting temperature ofa brazing material whereupon said ferrule portion is annealed tosubstantially a dead soft condition, simultaneously therewith coolingsaid tongue portion to maintain same below annealing temperature;removing said heated ferrule from the heating means, and applyingimmediately a predetermined amount of a thin strip of brazing materialalong said seam until said brazing material is melted by the heat ofsaid ferrule portion only.

2. In the art of fabricating from sheet metal connectors having awork-hardened tongue portion and an annealed readily crimpable ferruleportion adapted for cold forging onto conductors and the like, thatimprovement which comprises the steps of providing a connector elementof work-hardened malleable sheet metal having tongue and rolled upferrule portions, said ferrule portion having a longitudinal butt seamtherein; heating said ferrule portion to a temperature in excess of theannealing temperature of said sheet metal and the wetting temperature ofa brazing material whereupon said ferrule portion is annealed tosubstantially a dead soft condition, simultaneously therewith coolingsaid tongue portion to maintain same below annealing temperature;removing said heated ferrule from the heating means; positioning theconnector so that said butt seam is on the bottom of said ferrule andapplying immediately a predetermined amount of a thin strip of brazingmaterial along said seam until said brazing material is melted by theheat of said ferrule portion only and flows by capillary action upwardlyagainst gravity into said seam to form a smooth seam that requiressubstantially no removal of excess brazing material.

3. In the art of fabricating from sheet metal connec tors having awork-hardened tongue portion and an annealed readily crimpable ferruleportion adapted for cold forging onto conductors and the like, thatimprovement which comprises the steps of providing a connector elementof work-hardened malleable sheet metal having tongue and rolled upferrule portions, said ferrule portion having a longitudinal butt seamtherein; cooling said tongue portion to maintain same below annealingtemperature, heating said ferrule portion at a spaced interval from saidtongue portion to a temperature in excess of the annealing temperatureof said sheet metal and the wetting temperature of a brazing materialwhereupon said ferrule portion is annealed to substantially a dead softcondition, removing said heated ferrule from the heating zone; andapplying immediately a predetermined amount of a thin strip of a brazingmaterial along said seam until said brazing material is melted by theheat of said ferrule portion only, whereby there is provided acompletely annealed ferrule portion connected to the tongue portion by azone of metal of gradually increasing hardness.

4. The improvement as defined in claim 1 in which said brazing materialis applied laterally onto said seam whereby the braze flows into saidseam only against gravity by capillary action and wetting of the metal.

5. The improvement as defined in claim 1 in which said strip of brazingmaterial and said seam are at an acute angle as they are brought intocontact.

6. The improvement as defined in claim 1 in which said ferrule portionis held tilted up with its seam on its lower side when said strip ofbrazing material and said seam are brought together, whereby the brazingmaterial fiows into the seam by surface action against gravity.

References Cited in the file of this patent UNITED STATES PATENTS 18,327Darling Oct. 6, 1857 993,195 Phelps May 23, 1911 1,457,504 Cullen et al.June 5, 1923 1,615,591 Mallory Jan. 25, 1927 1,828,977 Miller Oct. 27,1931 1,969,840 Goddard Aug. 14, 1934 2,303,467 Inskeep Dec. 1, 19422,371,469 Rogolf Mar. 13, 1945 2,424,794 Brown July 29, 1947 2,452,932Johnson Nov. 2, 1948 OTHER REFERENCES Steel, June 8, 1942, pages and102.

1. IN THE ART OF FABRICATING FROM SHEET METAL CONNECTORS HAVING AWORK-HARDENED TONGUE PORTION AND AN ANNEALED READILY CRIMPABLE FERRULEPORTION ADAPTED FOR COLD FORGING ONTO CONDUCTORS AND THE LIKE, THATIMPROVEMENT WHICH COMPRISES THE STEPS OF PROVIDING A CONNECTOR ELEMENTOF WORK-HARDENED MALLEABLE SHEET METAL HAVING TONGUE AND ROLLED UPFERRULE PORTIONS, SAID FERRULE PORTION HAVING A LONGITUDINAL BUTT SEAMTHEREIN; HEATING SAID FERRULE PORTION TO A TEMPERATURE IN EXCESS OF THEANNEALING TEMPERATURE OF SAID SHEET METAL AND THE WETTING TEMPERATURE OFA BRAZING MATERIAL WHEREUPON SAID FERRULE PORTION IS ANNEALED TOSUBSTANTIALLY A DEAD SOFT CONDITION, SIMULTANEOUSLY THEREWITH COOLINGSAID TONGUE PORTION TO MAINTAIN SAME BELOW ANNEALING TEMPERATURE;REMOVING SAID HEATED FERRULE FROM THE HEATING MEANS, AND APPLYINGIMMEDIATELY A PREDETERMINED AMOUNT OF A THIN STRIP OF BRAZING MATERIALALONG SAID SEAM UNTIL SAID BRAZING MATERIAL IS MELTED BY THE HEAT OFSAID FERRULE PORTION ONLY.